This study aimed to enhance the performance of dental resin composites (DRCs) by increasing the content of inorganic fillers while addressing potential health risks associated with Bisphenol A (BPA). To achieve this, the BPA-based resin monomer Bis-GMA was replaced with BPA-free Bis-EFMA. The study then explored the impact of varying inorganic filler contents on the physiochemical properties of Bis-EFMA-based bulk-fill dental resin composites (BF-DRCs). Four distinct Bis-EFMA-based BF-DRCs were formulated, each with different inorganic filler contents ranging from 70 wt% to 76 wt%. The study tested the depth of cure (DOC), double-bond conversion (DC), water sorption (WS), solubility (SL), and cytotoxicity of the system. It notably investigated the effects of increasing filler content on mechanical properties through flexural strength (FS), flexural modulus (FM), Vickers microhardness (VHN), and wear resistance, as well as the impact on polymerization shrinkage, including volumetric shrinkage (VS) and shrinkage stress (SS). To assess the commercial application potential of Bis-EFMA-based BF-DRC, the research used the commercially available BF-DRC Filtek Bulk-Fill Posterior (FBF) as a control. The results indicated that a higher filler content did not affect the DOC of Bis-EFMA-based BF-DRCs. Inorganic fillers at higher concentrations significantly enhanced overall mechanical properties while significantly reducing volumetric shrinkage (VS; p < 0.05). When the concentration of inorganic fillers in the resin system reached 76 wt%, most of the performance of the Bis-EFMA-based BF-DRC surpassed that of the commercial control FBF, except for FS, FM, and SS. These findings highlight the potential of Bis-EFMA-based BF-DRC as a long-term restorative material for dental applications.
